Rail and panel system for a pontoon boat

ABSTRACT

The invention relates to boundaries used on a watercraft. Specially, the invention relates to boundaries used on pontoon boats. The boundaries generally include a rail and panel system positioned around an outer periphery of the pontoon boat. The invention also relates to a method of forming and installing the boundaries on a watercraft.

This Continuation-In-Part application claims the benefit of U.S. patent application Ser. No. 11/132,483 filed May 19, 2005, the complete disclosure of which is hereby expressly incorporated by reference.

FIELD OF THE INVENTION

The invention relates to boundaries used on a watercraft. Specially, the invention relates to boundaries used on pontoon boats.

BACKGROUND OF THE INVENTION

Watercraft such as pontoon boats generally include a plurality of rails supported by the deck of watercraft. The rails sometimes are positioned around the outer periphery of the deck to prevent passengers from falling overboard and to provide support of passengers. Typically, the rails cooperate with the deck or some other area of the watercraft to enclose a panel. The rail and panel may form a boundary around the outer periphery of the watercraft. In general, the panels are constructed of a metal such as aluminum.

BRIEF SUMMARY OF THE INVENTION

One embodiment of the invention includes a watercraft including a frame, a rail supported by the frame, and a non-metallic panel supported by the rail.

Another embodiment of the invention includes a watercraft including a frame, a rail member supported by the frame, a panel member coupled to the rail, and means for coupling the panel member to the rail member.

Another embodiment of the invention includes a boundary for a watercraft, the boundary comprising a rail including a recessed portion and an extension, and a panel including first and second ends, the first end including an interlocking portion.

Another embodiment of the invention includes a method of manufacturing a watercraft, comprising the steps of providing a flotation platform, extruding a plurality of rails, defining a rail structure by attaching the plurality of rails to the flotation platform, providing a polymer-based panel, and interlocking the polymer-based panel to the rails to define a boundary wall.

Another embodiment of the invention includes a boundary for a watercraft, the boundary comprising a rail including a recessed portion and an extension, a panel configured to be attached to the rail, and cooperative interlocking members associated with the panel and the rail, the members configured to attach the panel to the rail.

Another embodiment of the invention includes a method of making a rail for a watercraft, and for use with a panel having tabs along an edge thereof, the method including the steps of providing a metallic material, and extruding the metallic material to produce a tube having a substantially square cross section including an extension and a recess, the recess adjacent to the extension.

Another embodiment of the invention includes a pontoon boat including a flotation platform defining a perimeter, a motor supported by the flotation platform, a plurality of rails supported by the flotation platform, the rails positioned around the perimeter, the rails including a substantially square tube having a recess and an extension positioned adjacent the recess, the extension including a first tab, and a plurality of polymer-based panels having first and second ends and sides extending therebetween, each of the panels including a second tab on each side, the second tab configured to interlock with the first tab of the extension to secure the panels to the rail.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned and other features and objects of this invention, and the manner of attaining them, will become more apparent and the invention itself will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:

FIG. 1 is an elevated perspective view of a pontoon boat;

FIG. 2 is a cross-sectional view of one prior art embodiment of a rail used on a watercraft such as the pontoon boat shown in FIG. 1, the rail is shown in its preassembled configuration;

FIG. 3 is a partial cross-sectional assembly view of one embodiment of a rail and panel system through lines 3-3 of FIG. 1, and as shown, is configured to be used on a watercraft such as the pontoon boat shown in FIG. 1, the rails are shown in their preassembled configuration;

FIG. 4 is a partial cross-sectional assembly view of the rail and panel system shown in FIG. 3, with the rails shown in their assembled configuration;

FIG. 5 is a partial cross-sectional assembly view of another embodiment of a rail and panel system configured to be used on a watercraft such as the pontoon boat shown in FIG. 1, with the rails shown in their preassembled configuration;

FIG. 6 is a partial cross-sectional assembly view of the rail and panel system shown in FIG. 5, with the rails shown in their assembled configuration;

FIG. 7 is a partial cross-sectional assembly view of another embodiment of a rail and panel system using the rail shown in FIG. 2, the system is configured to be used on a watercraft such as the pontoon boat shown in FIG. 1, the rails are shown in their assembled configuration;

FIG. 8 shows a diagrammatical view showing a method of manufacturing the panel and rail system described;

FIG. 9 is a partial cross-sectional assembly view of another embodiment of a rail and panel system configured to be used on a watercraft such as a pontoon boat, as shown in FIG. 1, the rails are shown in their preassembled configuration; and

FIG. 10 is a partial cross-sectional assembly view of the rail and panel system shown in FIG. 9, with the rails shown in their assembled configuration.

Corresponding reference characters indicate corresponding parts throughout the several views. Although the drawings represent embodiments of the present invention, the drawings are not necessarily to scale and certain features may be exaggerated in order to better illustrate and explain the present invention. The exemplifications set out herein illustrate embodiments of the invention in several forms and such exemplification is not to be construed as limiting the scope of the invention in any manner.

DETAILED DESCRIPTION OF THE INVENTION

The embodiments discussed below are not intended to be exhaustive or limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may utilize their teachings.

A watercraft, generally indicated as 10, is shown in FIG. 1, and in this embodiment, watercraft 10 is a pontoon boat. Watercraft 10 includes a frame, generally indicated as 12, an engine, generally indicated as 14, pontoons 16, and deck 18. Watercraft 10 also includes a plurality of rails 20 and panels 22 supported by frame 12 and deck 18. Rails 20 are positioned above and below panels 22 to form a boundary around an outer periphery of deck 18 to safely surround passengers on watercraft 10.

A cross-sectional view of a prior art embodiment of one rail, generally indicated as 19, is shown in FIG. 2. Rails 19 are used similarly to rails 20 as shown in FIG. 1 to secure panels 22 to the watercraft to form an outer boundary of the watercraft. Each rail 19 is constructed of an extruded metallic tube and includes a rail member 17 having a substantially square profile. Rail 19 also includes an extension 15 coupled to one side of rail member 19. This configuration of rail 19 is commonly called a “Q tube.” Extension 15 includes a pair of teeth 21. A receiving area, generally indicated as 23, is formed between extension 15 and rail member 17. In FIG. 2, rail 19 is shown in the unassembled orientation. In use, a panel, such as panel 22 in FIG. 1, is positioned in receiving area 23, and extension 15 is bent or crimped toward rail member 17 to secure the panel in receiving area 23 in position. Teeth 21 engage the panel when extension 15 is crimped.

A partial cross-sectional view of an embodiment of upper and lower rails 20 in accordance with the present invention with one panel 22 positioned between is shown in FIGS. 3 and 4. Upper and lower rails 20 are identical with respect to form and function and differ only in orientation. Panel 22 is shown in partial for simplicity, and it should be understood that opposite ends are also substantially identical and only differ in orientation.

As shown in FIG. 3, each rail 20 includes a rail member 24, an extension 26, and a recess or recessed area 30. In this embodiment, rail 20 is an extruded aluminum tube. In other embodiments (not shown), rail 20 may be constructed of another metallic material, a non-metallic material, or any other suitable material. Rail member 24 has a substantially square profile and a hollow central region. Rail member 24 includes a side, generally indicated as 25, from which an extension 26 extends. Side 25 and extension 26 form a receiving area, generally indicated as 29, for receiving an end of panel 22, as will be described herein. Extension 26 extends from side 25 of rail member 24 and includes an interlocking or engaging portion 28, which is shown as a tab, positioned at one end of extension 26. A recessed area or recess 30 is formed in side 25 of rail member 24. As shown in FIG. 3, in this embodiment, recessed area 30 extends about half of the length of side 25.

Panel 22 includes a panel member 32, which is continuous between an upper end 31 and a lower end 33. Upper and lower ends 31 and 33 each include an interlocking or engaging portion 34, which is shown as a tab that extends substantially perpendicularly from panel member 32. In this embodiment, panel 22 is constructed of polycarbonate. Polycarbonate is dent- and scratch-resistant and has excellent thermal expansion, toughness, and forming capabilities. Additionally, polycarbonate has heat deflection properties and can be produced in a wide variety of colors, which may reduce the need for further processing such as painting. Supplemental components, such as ultraviolet blockers and stabilizers, may be added to polycarbonate to optimize the polycarbonate for the desired application. It should be understood that panel member 22 may be constructed from a polymer-based material, a non-metallic material, or any other suitable material.

It should be appreciated that FIG. 3 shows a preassembled position, where panel 22 is shown poised for interconnection to rails 20. In this position, upper end 31 and lower end 33 of panel member 32 are positioned in corresponding recessed areas 30, with respective interlocking portions 34 extending in an overlapping manner with interlocking portions 28 of extensions 26.

Referring now to FIG. 4, rails 20 are shown with extensions 26 bent or crimped to secure panel 22 in position between upper and lower rails 20. When extensions 26 are crimped, interlocking portions 28 interlock with respective interlocking portions 34 to secure panel member 32 in recessed areas 30. As shown in FIG. 1, rails 20 and panels 22 extend along the length of watercraft 10. Assembly of the boundary formed by rails 20 and panels 22 generally includes the steps of positioning a panel 22 between upper and lower rail 20, as shown in FIG. 3, and providing a roller or other crimping device (see FIG. 8) configured to bend extensions 26 from the position shown in FIG. 3 into a position to secure panel 22, as shown in FIG. 4.

With reference now to FIGS. 5 and 6, another embodiment will be described. In this embodiment, upper and lower rails, generally indicated as 40, are provided and positioned to cooperate with a panel, generally indicated as 52. Upper and lower rails 40 each include a rail member 42, an extension 44, a recess or recessed area 48, and a receiving area, generally indicated as 50. In this embodiment, recess 48 defines a notch. Panel 52 includes a panel member 54 and interlocking portions 56, which are shown as tabs. Panel 52 is substantially similar to panel 22 with the exception that the orientation of the interlocking portions is reversed relative to the rails 40, that is, interlocking portions 56 are facing towards rails 40 rather than away from rails 40. Rails 40 are similar to rails 20 with the exceptions that extensions 44 do not include interlocking portions and recesses 48 are configured to accept interlocking portions 56 of panel 52.

As shown in assembled view FIG. 6, extensions 44 are bent or crimped, as described above, toward rail members 42 to contact panel member 54 and secure interlocking portions 56 in recesses 48. Interlocking portions 56 interlock with rail members 42 in recesses 48. Extensions 44, interlocking portions 56, and recesses 48 prevent panel 52 from becoming dislodged if a force is applied to flex panel member 54.

Another alternative embodiment of the rail and panel system is shown in FIG. 7. This rail and panel system utilizes rails 19 of FIG. 2 and a non-metallic panel, generally indicated as 70. Rails 19 and panel 70 are shown in an assembled partial cross-sectional view in FIG. 7. As discussed above, rail 19 includes an extension 15 having teeth 21. Non-metallic panel 70 is substantially flat and includes ends 72, which are configured to be positioned in receiving areas 23 (not shown) of rails 19 during assembly. Extensions 15 are then crimped, which is described below, to secure panel 70 in position. Teeth 21 on extensions 15 contact ends 72 of panel 70 to secure panel 70 between rails 19. In this position, non-metallic panel 70 directly contacts rail members 17 and extensions 15.

With reference now to FIG. 8, a method of installing the rail and panel system will be described. The method is shown with the rail and panel system of FIGS. 3 and 4, but the method is equally applicable to the embodiments of FIGS. 5, 6 and 7.

With respect to the manufacturing of the rails themselves, the rails may be extruded from a material such as aluminum. The cross section of rails 20 or 40 is conducive to an extrusion process, as all of the configuration is continuous along its entire length. That is, for instance, in the embodiment shown, rail 20 is designed such that all of the features, including rail member 24, extension 26, interlocking portion 28, and recess 30, are continuous along the entire length of the rail, which may make an extrusion process a suitable means for producing rails 20 or 40.

Once the rails are provided, the panel is provided. In one embodiment, panels 22, 52 may be formed by a molding or extrusion process. The configuration of panels 22, 52 is also compatible for either process. In either case, the panels are formed to include the interlocking portions 34 at the upper and lower ends 31, 33 of panel 22. It should be appreciated that the panels are formed such that the interlocking portions are spaced apart at the proper distance between extensions 26.

Once two rails are positioned as shown in FIG. 3, the panel 22 can be slidably received longitudinally into the receiving areas 29, until the panel 22 is fully installed. At that point, a crimping roller, such as 60 (FIG. 8), which is rotatable about axis A-A, can be used to crimp extensions 26 into place. For example, roller 60 can begin at one end of rail 20 and move longitudinally along the length of rail 20 to roll the extensions from the preassembled position of 26-1, shown in outline form, to the assembled position of 26-2, where interlocking portions 28 overlap and interlock with interlocking portions 34.

Now referring to FIGS. 9 and 10, another alternate embodiment of a rail and panel system is shown. The rail and panel system utilizes upper and lower rails, generally indicated as 80, respectively. Rails 80 may be an extruded aluminum tube or may be constructed using another process or another metallic material, non-metallic material or any other suitable material. Rail member 84 has a substantially square profile and a hollow central region. Each rail member 84 also includes a side, generally indicated as 85, from which an extension 86 extends. Side 85 and extension 86 form a receiving area, generally indicated as 89 (FIG. 9), for receiving an end of a panel, generally indicated as 100, as will be described herein. Extension 86 extends from side 85 of rail member 84 and includes an interlocking or engaging portion 88, which is shown as a tab or a lip, positioned at one end of extension 86. In this embodiment, a recessed area or recess 90 is formed in side 85 of rail member 84. In this embodiment, recessed area 90 extends about one-half of the length of side 85.

Panel 100 includes a panel member 102, which is continuous between an upper end 101 and a lower end 103. Upper and lower ends 101 and 103 each include an interlocking or engaging portion 104, which is shown as a tab or a lip that faces away from rail members 84. In the embodiment shown, interlocking portions 104 form an acute angle with a face of panel member 102. Panel member 102 may be constructed of a polycarbonate or may be constructed from another polymer-based material, a non-metallic material, a metallic material, or other suitable material.

FIG. 9 shows a preassembled position, where panel 100 is shown poised for interconnection to rails 80. In this position, upper end 101 and lower end 103 of panel member 102 are positioned in corresponding recessed areas 90, with respective interlocking portions 104 extending in an overlapping manner, with interlocking portions 88 of extensions 86.

Referring now to FIG. 10, rails 80 are shown with extensions 86 bent or crimped, such as with a crimping roller 60 shown in FIG. 8, to secure panel 100 and positioned between upper and lower rails 80. When extensions 86 are crimped, interlocking portions 88 interlock with respective interlocking portions 104 to secure panel member 102.

While this invention has been described as having an exemplary design, the present invention may be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. For example, most of the embodiments depicted can be manufactured without a recessed area on the rail adjacent the extension. In addition, the shape, size and orientation of the interlocking portion or tabs on the extension and panel can be modified to other suitable forms. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains. 

1. A watercraft including: a frame; a rail supported by the frame; and a non-metallic panel supported by the rail.
 2. The watercraft of claim 1, wherein the non-metallic panel is constructed of a polymer-based material.
 3. The watercraft of claim 1, wherein the non-metallic panel is constructed of polycarbonate.
 4. The watercraft of claim 1, wherein the watercraft is a pontoon boat.
 5. The watercraft of claim 1, wherein the rail and the non-metallic panel cooperate to define a boundary of the watercraft.
 6. The watercraft of claim 1, wherein the rail is formed from a substantially square-shaped tube.
 7. The watercraft of claim 1, wherein the non-metallic panel has interlocking portions adjacent to a top and bottom edge, that are profiled to interlock with the rail.
 8. The watercraft of claim 7, wherein the tube includes four sides and an extension coupled to one of the sides.
 9. The watercraft of claim 8, wherein the tube includes a recess adjacent to the extension.
 10. The watercraft of claim 9, wherein the extension includes a first tab cooperable with said interlocking portions.
 11. The watercraft of claim 10, wherein the interlocking portion on the non-metallic panel includes a second tab configured to cooperate with the recess and the first tab to couple the panel to the tube.
 12. The watercraft of claim 9, wherein the recess is defined as a notch and the interlocking portion of the non-metallic panel includes a second tab configured to be positioned in the notch.
 13. The watercraft of claim 7, wherein the non-metallic panel is configured to directly contact both the extension and one side of the tube including the extension.
 14. The watercraft of claim 1, wherein the non-metallic panel includes a panel member that defines a first plane and a tab extending from the panel member substantially perpendicularly relative to the first plane.
 15. The watercraft of claim 1, wherein the non-metallic panel includes a panel member that defines a first plane and a tab extending from the panel member angles backward to form an acute angle to the first plane.
 16. The watercraft of claim 1, wherein the non-metallic panel is configured to couple directly to the rail.
 17. A watercraft including: a frame; a rail member supported by the frame; a panel member coupled to the rail; and means for coupling the panel member to the rail member.
 18. The watercraft of claim 17, wherein the panel member is constructed of a polymer-based material.
 19. The watercraft of claim 17, wherein the means for coupling the panel member to the rail member includes a tab positioned on the panel member.
 20. The watercraft of claim 17, wherein the means for coupling the panel member to the rail member includes a recessed portion in the rail member.
 21. The watercraft of claim 17, wherein the means for coupling the panel member to the rail member includes an extension coupled to the rail member.
 22. A boundary for a watercraft, the boundary comprising: a rail including a recessed portion and an extension; and a panel including first and second ends, the first end including an interlocking portion.
 23. The boundary of claim 22, wherein the interlocking portion of the panel is configured to be positioned in the recessed portion of the rail to couple the panel to the rail.
 24. The boundary of claim 23, wherein the extension is configured to bend to contact the interlocking portion of the panel to couple the panel to the rail.
 25. The boundary of claim 22, wherein the extension includes a tab configured to correspond to the interlocking portion of the panel to couple the panel to the rail.
 26. The boundary of claim 22, wherein the panel is constructed of a polycarbonate material.
 27. The boundary of claim 22, wherein the rail includes four sides and one of the sides includes both the recessed portion and the extension.
 28. The boundary of claim 22, wherein the first and second ends of the panel define a first plane, and the interlocking portion is substantially perpendicular to the first plane.
 29. The boundary of claim 22, wherein the first and second ends of the panel define a first plane, and the interlocking portion angles backward to form an acute angle to the first plane.
 30. A method of manufacturing a watercraft, comprising the steps of: providing a flotation platform; extruding a plurality of rails; defining a rail structure by attaching the plurality of rails to the flotation platform; providing a polymer-based panel; and interlocking the polymer-based panel to the rails to define a boundary wall.
 31. The method of claim 30, wherein the flotation platform is defined as a pontoon boat platform.
 32. The method of claim 30, wherein the flotation platform defines a periphery and the rail structure is supported by the flotation platform around the periphery.
 33. The method of claim 30, wherein the rails are extruded to define a generally Q-shape.
 34. The method of claim 33, wherein the Q-shaped rails are extruded to define a generally square cross section with an extending portion.
 35. The method of claim 33, wherein the polymer-based panel and the rails are interlocked to each other by providing an interlocking tab on the panel adjacent to an edge of the polymer-based panel.
 36. The method of claim 35, wherein the interlocking tab on the polymer-based panel is positioned in a receiving area between the square cross section and the extending portion, and the extending portion is crimped to form the interlocking engagement.
 37. The method of claim 35, wherein two Q-shaped rails are provided in parallel with the receiving areas positioned in a facing relationship, and the polymer-based panel is positioned between the parallel rails in the receiving areas.
 38. The method of claim 36, wherein the extending portion of the Q-shaped rails has a complementary overlapping tab and the overlapping tabs on the panel and the Q-shaped rails interlock the panel and rails together.
 39. The method of claim 36, wherein the Q-shaped rails are extruded to define a notch in the square portion and opposed to the extending portion, whereby the interlocking tab of the polymer-based panel is received in the notch, and the extending portion is subsequently crimped to entrap the panel.
 40. A boundary for a watercraft, the boundary comprising: a rail including a recessed portion and an extension; a panel configured to be attached to the rail; and cooperative interlocking members associated with the panel and the rail, the members configured to attach the panel to the rail.
 41. The boundary of claim 40, wherein the cooperative interlocking members include a first tab positioned on the extension and a second corresponding tab positioned on the panel.
 42. The boundary of claim 41, wherein the first tab is configured to interlock with the second tab to couple the panel to the rail.
 43. The boundary of claim 40, wherein the panel is constructed of a polycarbonate material.
 44. A method of making a rail for a watercraft, and for use with a panel having tabs along an edge thereof, the method including the steps of: providing a metallic material; and extruding the metallic material to produce a tube having a substantially square cross section including an extension and a recess, the recess adjacent to the extension.
 45. The method of claim 44, wherein the extension is provided with a tab for interlocking with the panel tab.
 46. The method of claim 44, wherein the recess is provided as a notch for receiving the panel tab.
 47. A pontoon boat including: a flotation platform defining a perimeter; a motor supported by the flotation platform; a plurality of rails supported by the flotation platform, the rails positioned around the perimeter, the rails including a substantially square tube having a recess and an extension positioned adjacent the recess, the extension including a first tab; and a plurality of polymer-based panels having first and second ends and sides extending therebetween, each of the panels including a second tab on each side, the second tab configured to interlock with the first tab of the extension to secure the panels to the rail.
 48. A method of manufacturing a watercraft, comprising the steps of: providing a flotation platform; extruding a plurality of rails; defining a rail structure by attaching the plurality of rails to the flotation platform; providing a non-metallic panel; and coupling the non-metallic-based panel directly to the rails to define a boundary wall.
 49. The method of claim 48, wherein the rails are extruded to define a generally Q-shape.
 50. The method of claim 49, wherein the Q-shaped rails are extruded to define a generally square cross section with an extending portion.
 51. The method of claim 50, wherein the non-metallic panel is positioned in a receiving area between the square cross section and the extending portion, and the extending portion is crimped to contact the non-metallic panel.
 52. The method of claim 51, wherein the non-metallic panel includes a tab that angles backward to form an acute angle between the tab and the non-metallic panel. 